Aero Shell

Info

The Aeroshell was designed around the vehicle frame and a 95th percentile male model, meaning it can comfortable fit two 6'2" riders. The majority of the designing was done using AutoCAD. The first version of the design was based on early sketches of the frame and the rider positions. Version 2 shows the riders in a more reclined position, and thus a longer, narrower shell. The Version 2 model was imported into JavaFoil and COMSOL to analyze its aerodynamics. Both programs showed a rather large low pressure wake behind the vehicle. Version 3 reflects changes in aerodynamics (an elongated tail) and more room for the pedaller's feet (a wider, blunter nose). This version was also used to create the 3D model in SolidWorks, and to build the shell mold.

The shell mold was glued together from sheets of insulation foam, which was then carved into shape (see the front page for construction pics). Sheets of Zotefoam were then stretched over the mold, and heat formed to the contours. Once the individual sheets were heat formed and trimmed, they were glued to each other using contact cement. The final step was to attach the hatches and cut the side doors.

CAD Drawings

3D Side.jpeg
3D Front.jpeg
3D Iso.jpeg
Three Views.jpg
Zote Guide Side.bmp
Zote Guide Profiles.bmp
Shell_Side_v3.bmp
Shell_Top_v3.bmp
Shell_Side_v2.bmp
Shell_Top_v2.bmp
Shell_Side_v1.bmp
Shell_Top_v1.bmp

Other Images

NACA_duct.jpg
JavaFoil Side.bmp
JavaFoil Top.bmp
JavaFoil Top Streamlines.bmp
COMSOL Analysis.jpg

CAD Files

Readme1.txt
Shell_3.dwg
ProE.dwg
Shell_3.SLDPRT
Shell_3_Solid.SLDPRT
Shell_3_Solid_Half.SLDPRT
Shell_3_Surface.SLDPRT
Shell_3_Thin_Loft.SLDPRT

Other Files

Readme2.txt
Shell_3_Solid_Half_ASCII.STL
Shell_3_Solid_Half_Binary.STL
Shell_3_Thin_Loft_ASCII.STL
Shell_3_Thin_Loft_Binary.STL
Points_Graph.xls
Drag.xls
Rollover_Stability_2.xls
NACA_Submerged_Duct_Design.pdf
Heisler 2002 Adv_Veh_Des.pdf

Links

Zote Foam
Barracuda Fairing
JavaFoil
Mr. Fiberglass
Coroplast

List of Materials

  • Owen Corning foam insulation for plug
  • Wood Glue
  • Plenty of Masking Tape
  • Contact Cement
  • Zotefoam
  • Plywood/Cardboard for templates
  • Plastic for bubble
  • Plastic Laminate?

Updates

10/15 Uploaded a whole bunch of CAD files, along with some Excel sheets, and a short description of everything. -JP
5/8 Posted the 3D CAD drawings, with the proper coloring. Also posted another Javafoil pic and a COMSOL pic. -JP
4/8 Posted most recent Shell CAD drawings (ie version 3, which the mold is based on). Posted the JavaFoil screen caps that were included in the Winter Progress Report. Posted an image of a NACA duct, along with the original NACA document. -JP
2/11 Posted Drag spreadsheet. Updated shell pics coming soon, along with dimensions. -JP
1/31 Posted first version of the shell design, along with the CAD file. Also posted the PDF I was referencing. -JP
1/28 Added more links, and created a list of materials. CAD drawings to be posted soon. -JP
1/19 Created page, added link for Barracuda fairing design and JavaFoil applet. -JP

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